Loop pile carpet fabric



May 11, 1954 E. c. BLOCH er AL LOOP PILE CARPET FABRIC Filed July 11, 1952 Patented May 11, 1954 UNITED STATES PATiZNT OFFICE 2,677,871 LOOP PILE CARPET FABRIC Elsie C. Bloch and New York Godfrey Bloch, N. Y.

Application July 11, 1952, Serial N0. 298,401 8 Claims. (Cl. 28-74) This invention relates to improvements in various types of fabrics, including loop pile An object of the invention is to produce a a substantially non-directional texture and appearance which may be suitable for floor coverings, woven and knit apparel, and

A further object of the invention is the production of such fabric constructions as would normally otherwise have textured lines across the width but which,

Further objects and advantages of the invention will be apparent from the specification.

particularity vention, itself, however, both as to its slightly fuller, and another slightly tighter than adjacent rows. of this phenomenon is that the repeat all the loops tend to line up clearly in one direction giving the fabric a lined elTect.

This is a texture line across the width which is due to a repeat of the harness pattern. This type of line is distinguished from the line that appears in other carpets which are in the nature row of pile threads A result While not necessarily displeasing in itself, this line spoils the possibility of making non-directional fabrics which may plete straightness in weaving This texture line which bien A hard twisted looped pile fabric made according to this invention, and having the non-directional aspect as exemplled in Fig. 1, may be punching with sewing needles through a back,

or by any other method.

Furthermore, the method of the present invention may be applied to pile heights of from fG/r to gn.

A back coating is painted or otherwise applied on the back of the carpet to hold eiectively and permanently the loops and bers firmly in place, and as this backing material is or boucle appearance, in which some of the loops assume a position much lower or closer to the ground than others. Piece-dyeing enhances the non-directional character of the fabric produced by the methods of the present invention.

By the term hard twist We include also plied yarns hard-twisted together, even though they may contain elements not hard-twisted in their original state.

We have found after trial over extended time that the only method practicable for the production of patternless substantially non-directional stock dyed hard twist loop fabrics of the pile height in question is to use some yarns of S twist and some yarns of Z twist. As is well known in the art, an one direction, while a so-called Z twist is twisted in the opposite direction. 1n a single yarn, the Z twist is known as the regular twist, and the S twist is known as the reverse twist. Fig. 3 illustrates this arrangement wherein there are mounted in base A. a loop B, the yarn of which is twisted in one direction, and adjacent thereto a loop C, the yarn of which is twisted in the opposite direction. It will be understood thatv in the mass, a multiplicity of these loops of opposite twist will produce a patternless and substantially non-directional pile in the finished fabric.

Since plied yarns will be most often used in the practice of this invention, it should be stated that when S twist is used in the single, Z twist is normally used in the plying, and vice versa, when Z twist is used in the single, S twist will be used in the plying. This plying in the reverse direction of the single is designated in the trade as regular twist in the ply, although the use of reverse in the ply is not precluded.

We have found that by this expedient, constructions of hard twist uncut loops which show lines, boxes or various configurations without special weave pattern become substantially nondirectional and of even uniform patternless texture. Below are given two examples of construction in which the present invention has unique efcacy in the production of non-directional uniform results:

1. A woven fabric in which there are ground cotton ends and jute filling picks and in which the pile consists of 121/2 threads per inch of stock-dyed wool frieze of seven turns per inch twist, the same being fifty yards to the ounce "1- in weight. The fabric is woven by leno heddles over g" stationary gauges, for example, the loops being staggered and uncut, and every alternate pile thread being of reverse twist, the two ends weaving as one over the gauge.

2. A hooked fabric of uncut twist loops on a burlap back in which the yarns are hard twisted acetate rayon, seven turns per inch, fifty-ve yards per ounce. The loops are punched to a pile height 0f about Tse" made about fourteen rows to the inch, and about five loops to the inch in the long direction. The threads are alternately regular twist and reverse twist, one of each being hooked through the back, two as one. Both regular and reverse twist threads are hooked together through the same space in the back as if they were one thread.

It will be understood, however, that we can produce our non-directional weave either with the single yarn or with the ply yarns in accordance with the techniques of the present invention.

We can use plied yarns which are twisted in the same direction as the singles, although that would not normally be the practice in most instances. By using in the same fabric yarns which have opposite twist to each other (sometimes designated herein as S and Z twists, respectively) we mean to include, when speaking of plied yarns, yarns which are opposite to each other S twist yarn 1s twisted in altogether, the same is in the twist of the single, in the twist of the ply, or in the twists of both.

We have also found that certain constructions of soft or ordinary twist looped pile fabrics which would otherwise show a directional texture line across the width can also be made with a uniform substantially patternless non-directional appearance by means of the method of the present invention. For example, we have produced such a woven pile fabric in which there are ground cotton ends and jute filling picks and in which the pile consists 0f 61/4 threads per inch of l ply wool yarn weighing 30 yards to the ounce of ordinary twist woven on leno heddles over T76" gauges, the loops being staggered and uncut, and every alternate warp thread being of a twist opposite to an adjacent warp thread.

Although good non-directional uniformity of appearance is achieved by the weaving methods described hereinabove, and although, as previously stated, piece dyeing may enhance the nondirectional aspect, this desirable appearance may be further enhanced in some cases after weaving and in other cases after dyeing, by a physical treatment such as passing the woven fabric between rollers, one of which has sharp protrusions which shear or cut the pile in some places to deform, cut or tear the loops. The deformation of the loops may also be accomplished by other suitable mechanical means, with or without the actual cutting of the loops.

By non-directional patternless, we means such uniformity of color that, regardless of the way the pile is crushed, or of the direction that light strikes the same, with good workmanship and judgment, it may be used effectively joined side to end. The word patternless does not exclude texture but does exclude figured patterns.

In the specification, we have explained the principles of our invention, and the best mode in which we have contemplated applying those principles, so as to distinguish our invention from other inventions; and we have particularly pointed out and distinctly claimed the part, mode or combination which we claim as our invention or discovery.

While we have shown and described certain preferred embodiments of our invention, it will be understood that. modifications and changes may be made Without departing from the spirit and scope thereof, as will be clear to those skilled in the art.

We claim:

1. A looped pile fabric comprising an arrangement of hard twisted pile yarns, a substantial number of said yarns being twisted in one direction and distributed throughout the fabric, and the remaining yarns being substantial in number and being twisted in the opposite direction and distributed throughout the fabric, said yarns being combined to produce a patternless substantially non-directional pile.

2. A fabric according to claim 1 and further comprising a back coating material from which the pile loops above the ground are substantially free.

3. A looped pile fabric wherein each loop comprises a pair of hard twist yarns and wherein one of said yarns is twisted in one direction and the other of said yarns is twisted in the opposite direction, said loops being combined to produce a substantially non-directional patternless pile.

4. A looped pile fabric comprising an arrangement of pile yarns, a substantial number of said yarns being twisted in one direction and distributed throughout the fabric, and the remaining yarns being substantial in number and being ternless pile.

5. A looped pile fabric comprising pairs of loops loop of each pair isk wherein the yarn of one twisted in one direction and the yarn of the other loop of each pair is twisted in the reverse direction, said loops being combined to produce a substantially non-directional patternless pile.

6. The method of minimizing pattern and direction of texture in the manufacture of looped pile fabrics which comprises twisting a substantial number of the yarns of the fabric in one direction and distributing them throughout the fabric and twisting a substantial number of the other yarns in the reverse direction and distributing them throughout the fabric.

7. The method of minimizing pattern and direction of texture in the manufacture of looped pile fabrics having a plurality of pairs of loops distributed throughout the fabric, which comprises twisting the yarn of one loop of each pair in one direction and twisting the yarn of the other loop of each pair in the reverse direction.

8. A looped pile fabric comprising an arrange- Y ment of pile yarns, a substantial number of said yarns being twisted in one direction and distributed throughout the fabric,

and the remaining yarns being substantial in number and being twisted in the opposite direction and distributed throughout the fabric, said yarns being combined to produce a substantially non-directional patternless pile, and a back coating material from which the pile loops above the ground are substantially free.

References Cited in the file of this patent Number Number UNITED STATES PATENTS 

